Structure Problems of Ford Fusion

Ford Fusion owners have reported 34 problems related to structure (under the structure category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford Fusion based on all problems reported for the Fusion.

1 Structure problem of the 2017 Ford Fusion

Failure Date: 07/05/2024

The contact owns a 2017 Ford Fusion. The contact stated that while placing her grandchild in the car seat in the rear of the vehicle, she became aware of mold inside the vehicle. The contact stated that the rear passenger’s side and the trunk had mold. The contact stated that water had leaked into the vehicle from the overhead light. The contact stated she was constantly sick and had ear infections. The vehicle was taken to a dealer. The vehicle was inspected; however, the contact was unsure of the results. The dealer informed the contact that the failure was a known issue; however, the repair would be an out-of-pocket expense. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 60,000.

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2 Structure problem of the 2019 Ford Fusion

Failure Date: 11/14/2023

The contact owns a 2019 Ford Fusion energi titanium. The contact received notification of NHTSA campaign number:23v440000 (structure) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

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3 Structure problem of the 2014 Ford Fusion

Failure Date: 08/09/2023

The contact owns a 2014 Ford Fusion. The contact stated that while the vehicle was parked and being inspected, the mechanic observed that the sway bar was not properly bolted. The vehicle was diagnosed by a dealer. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 130,129.

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4 Structure problem of the 2014 Ford Fusion

Failure Date: 10/15/2018

2014 Ford Fusion. Consumer writes in regards to corrosion on vehicle. The consumer stated the manufacturer was made aware of the corrosion. The manufacturer denied assistance due to the vehicle being out of warranty.

5 Structure problem of the 2009 Ford Fusion

Failure Date: 01/10/2017

Takata recall. The contact owns a 2009 Ford Fusion. The contact received notification of NHTSA campaign number: 17v024000 (air bags). The parts to do the repair were unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The contact called bill cole Ford Lincoln at (606) 329-2120 (2119 greenup Ave, ashland, ky 41101) and glockner south point Ford at (740) 894-3673 (155 CO rd 406, south point, OH 45680) where it was confirmed that the parts were not available for the recall remedy. The manufacturer was not notified. The air bag warning indicator illuminated, indicating to remove objects near the passenger seat. The contact also stated that the glue that held the dashboard together was separated. The failure mileage was unknown. VIN tool confirms parts not available.

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6 Structure problem of the 2008 Ford Fusion

Failure Date: 07/14/2016

The contact owns a 2008 Ford Fusion. The contact stated that the air bag warning indicator illuminated at least four times per week for the past six months. The contact also mentioned that the dashboard became unglued near the air bag area. The contact was informed that the failure had nothing to do with the air bag warning indicator. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure mileage was 120,000.

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7 Structure problem of the 2009 Ford Fusion

Failure Date: 07/01/2016

Letter from senator nelson on behalf of constituent re 2009 Ford Fusion loaded with a takata airbag has not been resolved. The consumer stated the recall repair exceeded a reasonable amount of time. Updated 07/10/2017.

8 Structure problem of the 2016 Ford Fusion

Failure Date: 10/01/2015

2016 Ford Fusion. Consumer writes in regards to vehicle windshield and dashboard issues. The consumer stated when the sun shined through the windshield onto the dashboard, it reflected a 'v" above the instrument panel on the dashboard. The edges of the "v" reflected onto the inside of the front windshield and interfered with the driver's vision. The center cut out in the center of the dashboard also reflected onto the inside of the windshield, but since it was centered it did not interfere with the driver's vision. The consumer believed the reflection on the driver's windshield was a design defect. If the "v" was not cut into the dashboard above the instrument panel, there would be no reflection. If the dashboard was anti-glare the problem would probably be solved.

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9 Structure problem of the 2010 Ford Fusion

Failure Date: 01/27/2015

The contact owns a 2010 Ford Fusion. The contact stated that while at a traffic light and releasing the brake pedal, the vehicle accelerated independently to 60 mph. The contact lost control of the vehicle. The vehicle was taken to the dealer where it was diagnosed that the front driver side floor mat interfered with the accelerator pedal and needed to be replaced. The vehicle was repaired however, the failure recurred. The manufacturer was made aware of the failure. The failure mileage was 25,000.

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10 Structure problem of the 2015 Ford Fusion

Failure Date: 01/12/2015

The contact owns a 2015 Ford Fusion. The contact stated that while driving approximately 55 mph, there was a loud knocking noise heard when the rear window was open. The contact mentioned that the noise was caused by the pressured in the vehicle which worsen the faster the vehicle would go. The failure recurred on multiple occasions. The vehicle was taken to a dealer. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure was 126,000.

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11 Structure problem of the 2008 Ford Fusion

Failure Date: 07/09/2014

The contact owns a 2008 Ford Fusion. The contact stated that the passenger's side dashboard material was bulging where the air bag was located. The failure was not diagnosed by a dealer or an independent mechanic and the vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 70,000.

12 Structure problem of the 2006 Ford Fusion

Failure Date: 07/08/2014

The contact owns a 2006 Ford Fusion. The contact noticed a protrusion on the passenger side dashboard where the air bag was located. It appeared as if the air bag would deploy at any moment. The vehicle was taken to two mechanics who both stated that the protrusion was not caused by the air bag. The vehicle was taken to a body shop and the mechanic stretched the material to repair the dashboard and closed the opening that was created. The manufacturer was notified. The approximate failure mileage was 62,000.

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13 Structure problem of the 2006 Ford Fusion

Failure Date: 07/08/2014

The contact owns a 2006 Ford Fusion. The contact stated that the passenger side dashboard was separating which could possibly expose the air bag. The contact mentioned that the passenger side air bag light illuminated. The vehicle was taken to a dealer where it was diagnosed that the entire dashboard needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 53,000.

14 Structure problem of the 2008 Ford Fusion

Failure Date: 06/30/2014

The contact owns a 2008 Ford Fusion. The contact stated that the passenger¿s side dashboard was separating which could possibly expose the air bag. The vehicle was taken to a dealer where it was diagnosed that the entire dashboard needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 55,000.

15 Structure problem of the 2014 Ford Fusion

Failure Date: 01/23/2014

The interior of the car has a toxic smell from the carpet causing occupants to have migraine. The dealership steamed the carpet and it is same if not worse, I just don't believe it is safe for long trips especially in cold weather when opening the windows is foolish. Please advise on possible solutions. The dealership says there is nothing the can do to rid the car of the smell.

16 Structure problem of the 2013 Ford Fusion

Failure Date: 01/22/2014

While reaching over to my right to push a preselected radio selection button, I swerved to the right. No damage. But the placement of the radio tuner to the right of the console may cause other drivers to reach over and swerve.

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17 Structure problem of the 2008 Ford Fusion

Failure Date: 11/01/2013

I am the original buyer of a 2008 Ford Fusion se - which I purchased in 2008 - it now appears that there is a bulging near the passenger air bag area on my car's dashboard. This appears to be a manufacturing defect since the car has never been in any type of accident. Ford refuses to fix since car is no longer under warranty. I looked on line at it appears many other Ford Fusion owners are experiencing the same issue with the bulging dashboard. I am afraid this could lead to a deployment of the airbag. Ford will have dashboard fixed for over $1,200. 00 at my cost. How is this fair that I must pay for a manufacturing issue the Ford corporation created. Can you assist in any manner.

18 Structure problem of the 2008 Ford Fusion

Failure Date: 10/01/2013

2008 Ford Fusion sel awd: the dashboard cover is peeling up in front of the passenger side airbag. This has the potential to be a serious safety problem and is continuing to get worse as time passes. The vinyl cover appears to be delaminating from the foam rubber beneath it and could interfere with the proper deployment of the passenger side airbag in the event of a crash.

19 Structure problem of the 2008 Ford Fusion

Failure Date: 06/14/2013

I noticed the dash board around the airbag is separating about 2 months ago I tried to push the seam back down but it still puckers. Yesterday I tried to start my car and there was a continuous clicking sound coming from the dashboard and the security lock light and airbag light were flashing very fast. I just parked the car about 1 hour before and there was no problems until I came back to start it. I tried for about 1 hour but could not get it started. I have noticed there are a lot of complaints on this car and the same issues. This does seem like a recall issue. I wanted to support american made products from one of the oldest american auto makers. I am hoping you can fix this issue because I need to get the work and this is my only transportation. I live in an area where there is no public transportation. Thanking you in advance.

20 Structure problem of the 2007 Ford Fusion

Failure Date: 10/14/2012

The airbag is sticking out of the dashboard and Ford doesn't want to do anything about it. I believe that being this is safety concern and should be covered by Ford. I have contacted them because we have a concern that the airbag will fail or just blow out of the dashboard without any notice.

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21 Structure problem of the 2012 Ford Fusion

Failure Date: 08/13/2012

The contact owns a 2012 Ford Fusion. The contact stated that while driving the contact noticed the passenger side headlight would only illuminate partially. The vehicle was taken to the dealer for diagnostic testing. The technician stated the headlight was manufactured that way and no adjustment could be performed. Additionally, the contact stated the rear driver side door retained water inside when it rained or snowed. The technician stated there was a clog in the drain which would have to be cleaned. After the drain was cleared the failure continued. The vehicle was taken back to the dealer where the technician stated there was no repair for the failure. The contact was concerned of corrosion. The vehicle was not repaired. The approximate failure mileage was 1,500. The consumer stated the headlights were not aligned properly as she was unable to see the road at night. The dealer adjusted the headlights several times. Updated evoq 12/19/12.

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22 Structure problem of the 2010 Ford Fusion

Failure Date: 06/13/2012

I opened the storage console that sits on the dash and the lid broke off the hinges. Parts are made of that hard plastic the heat and sun bakes till brittle.

23 Structure problem of the 2011 Ford Fusion

Failure Date: 04/21/2012

2011 Ford Fusion. Consumer states safety issues with vehicle related to driver controls and distractions, battery failure and loss of electric power steering capability the consumer stated there was no warning that the steering was about to freeze while driving. The consumer also stated it was difficult to read the instrument panel. The headlight control was located in an inconvenient place, the obstruction of the left side plastic molding inside the steering wheel prevented a clear view of object.

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24 Structure problem of the 2007 Ford Fusion

Failure Date: 02/01/2012

2007 Ford Fusion. Consumer writes in regards to problems with dashboard and airbag on passenger side of vehicle. The consumer stated a year ago, the dashboard around the passenger side air bag became unglued and it is now sticking up. The consumer was informed it would cost $1100 to replace the entire dashboard. The consumer was concerned the air bag may not deploy if needed.

25 Structure problem of the 2006 Ford Fusion

Failure Date: 09/04/2011

First the rear driver's side interior door handle broke when my granddaughter was attempting to open it. Recently the front driver's side interior door handle broke. The fake chrome is peeling off of the passenger side both front and rear door handles. It was peeling off of the two handles that broke but I never thought that they would break. Although I am able to open the window to access the exterior door handle to open the door in most cases, the windows don't always open in the cold weather and the door is very difficult to open using the broken door handle. I am concerned I or a passenger will be stuck in the vehicle and not be able to get out in an emergency.

26 Structure problem of the 2010 Ford Fusion

Failure Date: 06/01/2011

The contact owns a 2010 Ford Fusion. The contact stated the passenger side front and drivers side vehicle studs were broken and replaced at multiple times. The vehicle was not taken to the dealer, and the manufacturer was not notified. The vehicle was not repaired. The failure mileage was 43,000 and the current mileage was 50,000.

27 Structure problem of the 2008 Ford Fusion

Failure Date: 05/29/2011

The contact owns a 2008 Ford Fusion. The contact stated that the vinyl on the dashboard where the air bag was located had been fractured. The vehicle was inspected by a dealer who advised her that it was a factory defect and that she needed to have the entire dash replaced. The vehicle was not repaired. The manufacturer was notified and offered no assistance. The failure mileage was approximately 53,000.

28 Structure problem of the 2008 Ford Fusion

Failure Date: 11/02/2009

My 2008 Ford Fusion purchased brand new also has the bulging dashboard on the front passenger side. It not only looks bad but who knows if the air bag will even deploy in a front end crash? I have also has catalytic converter replaced and today I need a new output speed sensor to the tune of another $500 in repairs. Car now has 130k mi.

29 Structure problem of the 2010 Ford Fusion

Failure Date: 10/31/2009

Safety issue. Design/engineering defect. 2010 Fusion hybrid. Foot space between the knee airbag housing and brake pedal is severely and dangerously restricted by the physical presence, bulk, and location of the knee airbag. This delays response for instant brake deployment for emergency deceleration. Vertical clearance is ~4" and is less if approached at an angle, swiveling on heel from accelerator to brake. Lifting foot with leg from hip bumps foot against airbag housing, stopping smooth transition to pedal with either foot. Foot then must slide horizontally into narrow space to engage brakes. Foot space is dangerously restricted even with driving mocs. I have excellent reflexes and 60-year safe driving record with no moving violations. But in congested freeway conditions during a 3600-mile road trip I felt required to drive with left foot poised above the brake pedal to limit emergency response time. With only short trips for 1500 miles, I at first thought I might get used to this problem. This limitation and the extraordinary driving practices required for safety only became painfully apparent during the road trip. This safety issue was reported to Ford motor company today. Desire physical removal of knee airbag with all mounting hardware and reprogramming of software to ignore its absence. Note: the required "incident date" on this form is the approximate date of manufacture, listed on the rocker panel as 10/09. This is an engineering design defect which appears to have been an afterthought. No accident has resulted only because I have devoted assiduous attention to mitigating the problem by shoe choice and extremely careful driving practice.

30 Structure problem of the 2006 Ford Fusion

Failure Date: 05/26/2009

2006 Fusion sel. 1) ignition key gets stuck in ignition. Approximately 9 incidents beginning may 2009 of parking the car, turning off the motor, key cannot be removed from ignition: 3-4 times the key could not be removed for over 48 hours; 4 - 5 times within 12 hours. . Car can be locked if using the second remote-control key, but will unlock all doors with in 5 seconds when lock on the inside door is pushed and door is closed. Have had the alarm go off 3 times when car door is opened after car left unattended for 15+ minutes, unlocked, with key stuck in ignition, but alarm has not sounded at all times for the same scenario. 2) chrome veneer on interior front door handles wrinkling and peeling. Problem was beginning to show it self when car was purchased.

31 Structure problem of the 2008 Ford Fusion

Failure Date: 11/13/2008

The contact owns a 2008 Ford Fusion. The contact noticed that field mice were entering the vehicle through the headliner. The failure could cause internal damage to the vehicle. He is in the process of taking the vehicle to the dealer to find out which component is allowing mice to enter the vehicle. He is waiting on a response from the manufacturer. The failure and current mileages were 5,088.

32 Structure problem of the 2006 Ford Fusion

Failure Date: 06/01/2008

I have a 2006 Ford Fusion that needs a paint job on the roof, because it is peeling. I bought the car new, and have owned it for less than two years. It has 39,000 miles on it, thus making it 3,000 miles out of warranty. Common sense and places I have taken it to consider this a defect.

33 Structure problem of the 2007 Ford Fusion

Failure Date: 05/15/2008

The contact owns a 2007 Ford Fusion. The contact stated that the dashboard on the passengers side was deteriorating near the air bag. The vehicle was taken to a private mechanic where it was diagnosed that the passengers side dashboard needed to be replaced. The manufacturer was notified of the failure. The vehicle was not repaired. The failure and the current mileage was 105,543.

34 Structure problem of the 2006 Ford Fusion

Failure Date: 05/01/2008

Driver's door interior handle has bent and does not open from the inside. Driver's side rear door interior handle has bent and sometimes will not open from the inside. Passenger side front door interior handle has bent but at this time still opens from the inside. Driver's door and driver's side rear door no longer lock due to this.


Other Common Structure related problems of Ford Fusion


Safety Ratings of Fusion Cars
Fuel Economy of Fusion Vehicles
Fusion Service Bulletins
Fusion Safety Recalls
Fusion Defect Investigations